Results for Medium Voltage Motors On-line Diagnostics

Dr. Yury P. Aksenov, Igor V. Yaroshenko, Giuseppe Noé, and Andrey V. Andreev

Abstract -- This paper represents an outline on On-Line Diagnostics Method Synergy (new
method: PD site location, vibration control and infrared control) including proactive maintenance
strategy which comprises the following sections: motors on-line testing and defects location
procedure; on-line diagnostic technology and data analysis; examples of test results, sensor
installation in detail, and example of technical report. The Benefits of on-line diagnostics are as
follows: determine—non-destructively—the probable extent of deterioration in service-aged
medium voltage motors, pinpoint the location of deterioration, determine which motors and cables
are likely to experience failure in the foreseeable future, decide whether wholesale replacement of
motor and cable is required, or just certain sections, postpone motor maintenance and postpone cost
of replacement. The conventional monitoring circuit system registers both wanted signal (PD) and
noises, but does not allow location, while the describes system determines the condition of service-
aged motors and cable lines: 1) this measuring technique pinpoints the actual place of defect in
stator winding, magnet core, terminal box, or cable line; 2) it reveals the type of discharge event—
PD, spark or arc—therefore acts noise-independently.

1. Introduction
In most rotating electrical machines, there are numerous potential defect sites of mechanical,
thermal and discharge events: PD in insulation; sparking between metal plates; arcing in contact,
vibration. Machine design, materials of construction, manufacturing methods, operating conditions,
and maintenance practices can profoundly affect the quantity, location, characteristics, evolution,
and the significance of partial discharges (PD).
A proactive rather than reactive maintenance strategy [1] is considered to determine the overall
health of the equipment, prioritize expenditures, stretch limited maintenance budgets, avoid costly
downtime, and develop a plan for remedial action. On-line condition-based monitoring of
equipment—PD monitoring—is becoming more and more widespread in the worldwide electricity
industry. Accurate condition assessment and the subsequent managements of in-service, high-
voltage plants are becoming more economically viable, with continuous advances and cost
reductions being made in sensor technology, data acquisition/processing and intelligent diagnostic
software. Although technology improvements continue apace, it is essential that the resultant data
be risk managed.
Condition-based maintenance of motors [2] is an important component of improving accessibility
of plants as well as making advantageous economic consideration as far as utilities permanently
have a clear incentive to assess the actual condition of strategically important units, with the aim to
minimize the risk of failures and to avoid forced outages. According to global experience in
conducted repairs, diagnostics are valuable both before repair, during the repair process, and after it
in order to check the repair quality [3]. Based on the International Standard, Diagnostic technology
is determined by the principle of conducting measurements on all stages of work; this standard
recommends different discharge events insulation data [4].
Induction motors are used worldwide as the workhorse in industrial applications. Such motors are
robust machines used not only for general purposes, but also in hazardous locations and severe
environments [5]. General purpose applications of induction motors include pumps, conveyors,
machine tools, centrifugal machines, presses, elevators, and packaging equipment. On the other
hand, applications in hazardous locations include petrochemical and natural gas plants, while severe
environment applications for induction motors include grain elevators, shredders, and equipment for
coal plants. Predictive maintenance program must include several techniques of monitoring of
electrical motor's condition for discharge activity, thermal events and mechanical problems
(vibrations). Among these vibration diagnostic techniques, probably the two ones that are related to
the capacitance current on ground (new technique) and vibration analysis. Unfortunately, in both
cases inherent drawbacks make difficult their use in loco on industry plants. According to published
surveys [6], [7], induction motor failures include bearing failures, inter-turn short circuits in stator
windings, cable line failure and broken rotor bars and end ring faults. On the basis of analysis (Fig.
1) bearing failures are responsible for approximately 30 percent of terminal box 20 percent.
Interturn short circuits in stator windings represent approximately one-third of the reported faults.
Broken rotor bars and end ring faults represent around ten percent of the induction motor faults [II]
For motor diagnostics method synergy.

2. Diagnostic Methods Synergy for Medium Voltage Motors

That means that there are main channels of motor’s degradation: 1) discharge activity (PD,
sparking, arcing); 2) vibration events; 3) heating.
Reliability of on-line diagnostics from Fig. 2 divided into steps is illustrated in Table 1 by
technical status and risk of failure.
The following tables explain testing and defects categorization procedure.
Table 1
Motor's technical status classification depending on class of defects

Technical status, risk of failure 1°, No risk 2°, Small risk 3°, Medium risk 4°, High risk

1) Corona activity on bars. Event Stable event Event develops Conversion to the
2) Sparking over contamination characteristics
occurrence registration dynamically limiting state (before
shutdown)
Event
PDs in ground wall insulation, characteristics Stable event Event develops Conversion to the
surface discharges registration dynamically limiting state (before
occurrence shutdown)
Class of defects

1) Slot discharge in stator Event characteristics Stable event Event develops

winding. 2) Discharges in rotor occurrence registration dynamically
winding.
Discharge in insulation and Event characteristics Stable event Event develops
sparking in terminal box occurrence registration dynamically
PD in cable line Event characteristics Stable event Event develops
occurrence registration dynamically
Bearing damage Event characteristics Stable event
occurrence registration
Shaft vibration Event characteristics Stable event Event develops
occurrence registration dynamically
Frame overheating Event characteristics Stable event Event develops
occurrence registration dynamically

Fig. 1. Typical Defects in Medium Voltage Motors: Results of Field on-line diagnostics.

Previously diagnostic results and their effectiveness were estimated and discussed mainly by the
use of one particular method. In the DMS for motors used by Diacs all physical events that can
result in damage are registered, the scheme is shown in Fig. 2, where: discharge activity (PD,
sparking and arcing); mechanical events (vibration); thermal events.
 As far as physical events are connected between each other, defects of one event will be
confirmed by other events, for example sparking in stator winding (defined by PD control) will
come together with excessive heating of the zone, where there are discharges. This is the principle
of synergy: below several diagnostic systems will be discussed.

Fig. 2. For motor diagnostic methods synergy - Diacs method of on-line testing, defect zone
location and schematic diagram of measuring system: I system – discharge activity measurements
and location: 1) outside temporarily installed on-frame sensors: TMP and HF CT; 2) instruments:
oscilloscope, PDPA-Analyzer. II system: capacitance current from stator winding on ground
analysis: 1) oscilloscope, 2) high sensitivity low frequency current transformer (LF CT); III system:
-infrared control; IV system: vibration control: 1-outside installed on-frame vibrosensors 2-
oscilloscope; V system – on-line PD in cable line measurements and location: 1) sensor HF CT, 2)
oscilloscope.

3. System Discharge Events measurements and Location

There are two types of on-line PD measuring circuits:
1. Usage of conventional circuit with coupling capacitor on terminal box;
2. New Diacs method with temporarily outside-installed sensors (Fig. 2, I system).
The conventional monitoring circuit system registers both wanted signal (PD) and noises, but
does not allow location, while Diacs system (Fig. 2) determines the condition of service-aged
motors and cable lines: 1) this measuring technique pinpoints the actual place of defect in stator
winding, magnet core, terminal box, or cable line; 2) it reveals the type of discharge event—PD,
spark or arc—therefore acts noise-independently.

4. System Vibration Events measurements and Location

There are two types of vibration techniques for measurements:
1. conventional vibration control (accelerometer usage) and current signature analysis (MCSA)
[8];
2. Diacs method with temporarily outside sensors [b. 4].
- New method – capacitors current from motor on ground signature analysis (CT6).
- High sensitivity (Frequency bend 0,1/ 10 000Hz) vibro-velocity sensor for vibration site
location.
This is mainly due to the importance of Induction Motor in industrial production processes.
Besides the widely used monitoring technique based on measuring mechanic vibrations mechanical
problems measurements with detection techniques based on Current Signature Analysis (MCSA)
[8] have proved efficiency in fault detection and diagnosis processes, not only for faults originated
electromagnetically but also mechanically.

5. Sensors Installation
Fig. 3 demonstrates location with oscilloscope and measurements of n(Q) spread schematic
diagram of discharge location circuits. Discharge sensors are installed on “1 o’clock and 12
o’clock” from Non-Drive End (NDE) plus on “13 o’clock and 24 o’clock” from Drive End (DE) in
Fig. 3 position 3. moreover, sensor is installed on the terminal box (Fig. 2, position 2).

Fig. 3. Sensors for discharge activity control, identification according to o’clock position.

6. Vibration Diagnostics Technologies

Diacs technology for vibration control consists of two steps: 1) capacitive current harmonics
analysis from stator winding to the ground allows determining the overall picture according to
quantity and defect categories (regardless to the noises) (see Fig. 2- system II); 2) for detected
defects (acc. to p.1) the location is performed, see Fig. 2, system IV. By means of sensor
measurements of a number of spots of the motor frame (Fig. 4).
The measured signals characteristics. The defects focused on this part are misalignment and
mechanical looseness, typical mechanical problems with a high probability of occurrence. The
characteristic signal in the case of misalignment (and no other fault simultaneously) obtained from
drive mechanism (pump). This fault is related to the coupling between the motor shaft and the pump
shaft, and occurs when they are parallel oriented but do not coincide (parallel misalignment), or
when they are not parallel but do coincide (angular misalignment). Both situations usually occur
simultaneously, with a characteristic signature of a high vibration at the frequencies equal to the
first, the second and the third multipliers of the shaft rotation frequency fsh (the 1x, 2x and 3x
harmonics), in both radial (horizontal and vertical) and axial directions.
Mechanical looseness is caused by structural looseness or weakness of machine fixation bases or
an improper fit between component parts, which causes high vibration energy in many harmonics
due to the nonlinear response of loose parts to dynamic forces of the rotor. Frequently, mechanical
looseness happens simultaneously with unbalance and misalignment, and usually causes a high
vibration component in the subharmonic 0.5 fsh and in the inter-harmonics, for example 1.5 fsh, 2.5
fsh and 3.5 fsh.
Vibration stator windings turn have the frequency multiple of 50 Hz. Vibrating plates in the
magnet core are as well multiple to 50Hz. Mechanical damages, for instance, bearings give a high
frequency 1-10 kHz.

7. DMS Results for a Group of Motors

According to Fig. 2. twenty six motors of high power capacity (3; 6 MW) were diagnosed, they
were in operation for more than 30 years. The final result of the testing is viewed in a Table 2 for all
motor, all defect categories and used motors.
For the given group of motors the major defect may be vibrations, therefore for this reason a
large description will be given below. A harmonics analysis will be given on the basis of features
selection (Fig. 4): - Capacitance currents from stator winding on ground; - Vibro velocity on many
points of the motor’s frame.
Results of the motor “6-2” with the presence of defects. Results of the multiparameter
diagnostics are given in Table 2.
 Table 2
Motor’s Technical Condition results According to the Diagnostics by Means of various Methods

OPERATION ANALYSIS,
MEASURING METHODS

AGING (IN OPERATION

CONTROL AND LOCATION OF

INFRA RED CONTROL

VIBRATION CONTROL
DISCHARGE ACTIVITY

SINCE 1974)

RESULTS
ANALYSIS IN
VIBRATION-

GROUNDING
HARMONIC
CURRENT’
SPARKING

ACOUSTIC
CONTROL
ARCING
PD
MOTOR COMPONENTS
Stator winding 10 10 10 10 10
Current lead 10 10 10
Insulation 10 20 10
Terminal box 20
Contacts 10 10
Magnet core 20 10 3
0 0
20 0
0
Rotor 1 10 10 3 3
Bearings
Terminator 10 10 10 10
Cable line
Line 10
Final conclusion 30
1) Discharge activity control – sparking and heating found in the terminal box
Sparking in the terminal box was found as well, signal in the bore which is situated in the center
of motor.
Technical condition according to discharge activity level - 30
2) Technical condition on the infrared control – Medium risk. Overheating in the terminal box.
3) Vibration control – a few major defects found.
Technical status: Medium risk”.
Capacitive currents harmonics analysis towards the ground (Fig. 7 a,b, c) and the vibration
velocity analysis according to points with the maximum level of vibration (d,e,f) is shown in fig.
13. Data from capacitive current harmonics analysis is the basic informational material (Fig. 7 a, d).
In the given figure three frequency bands are discussed: for lower reverse frequencies (frev =
11,2Hz) left column – curves (a, d). For higher frequencies that are multiple to frequencies of the
industrial line (50Hz) – see column “b, e” and for shock waves – see columns e and f.

Table 3
Results of Practical Application of Diacs Motors Diagnostic Methods Synergy for 26 Units of 3; 6
MW Motors
DISCHARGE ACTIVITY VIBROCONTROL
INFRARED
CONTROL

CAPACITORS CURRENT FINAL

WINDIN
TERMIN
STATOR

AL BPX

NO OF
ROTOR

CABLE

HARMONICS ANALYSIS
LINE

VIBRO CONCL RECOMMENDATIONS

MOTOR Not Parallel
Oriented Mechanical VELOCITY USION
Shafts Looseness
111, 113, No No risk No No No No risk No risk No risk No risk Operation without
No risk condition – 18

222, 224, risk risk risk risk restrictions. Test

311, 312, repeat in 3 years.
314, 324
motors

142 No No risk No No No No risk No risk Medium Mediu Operation in regular

risk risk risk risk risk m risk mode. Vibration Test
repeats in 1 year.
114 No No risk No No No No risk Small risk Small risk Small Operation in regular
risk risk risk risk risk mode. Test repeat in
1,5 years.
123 No No risk No No No No risk Small risk Small risk Small Operation in regular
Small risk condition

risk risk risk risk risk mode. Test repeat in

1,5 years.
– 5 motors

211 No No risk No No No No risk Medium risk Small risk Mediu Operation in regular
risk risk risk risk m risk mode. Vibration Test
repeats in 1 year.
214 No No risk No No No Small risk Small risk Medium Mediu Operation in regular
risk risk risk risk risk m risk mode. Vibration Test
repeats in 1 year.
 221 No No risk No No No No risk Small risk Small risk Small Operation in regular

condition – 3 motors
risk risk risk risk risk mode. Test repeat in
1,5 years.

Medium risk
322 No Small No No No No risk No risk No risk Small Operation in regular
risk risk risk risk risk risk mode. Test repeat in
1,5 years.
323 No Small No No No No risk No risk No risk Small Operation in regular
risk risk risk risk risk risk mode. Test repeat in
1,5 years.
Harmonics analysis was conducted within three frequency bands:
- in order to define the presence of sub harmonics ½ fsh, fsh, 2 fsh, etc. a 0-150Hz band is used;
-for defining the industrial frequency harmonics a 50Hz 100÷500 Hz is used.
- in order to detect the 500-5000Hz collision high frequency defects.
From the viewed above 26 motors two will be scrutinized, one of which in “no risk” conditions, #4.1.
the other # has some vibro-defects – “medium risk” – “n6.2”.

Fig. 5a. Harmonic analysis of capacitance currents from

motor No 322 to ground for the case when there are no
vibration defects. A – for 0-60Hz sub harmonics and
harmonics of shaft rotation frequency (fsh) and its
manifestation is the absence of misalignment defects.

Fig. 5b. Capacitance currents from motor No 4.1. to

ground for the case when there are no vibration defects. B –
for 10-500Hz harmonics of 50Hz – they show presence of
the 3, 5 and 7 harmonics its manifestation is the absence
vibration on the parts of winding and magnets.

Fig. 5c. Capacitance currents from motor No 4.1. to

ground for the case when there are no vibration defects. C –
for 500-2500Hz – no presence of vibration events in the
sound range.
DMS Results from motor No “4-1” (without defects) are
shown in Table 4.

Table 4
Motor No”4.1” Technical Status Characteristics According to Diagnostic Results by Various Methods
MEASURING METHODS CONTROL AND LOCATION OF
ANALYSIS, AGING

VIBRATION CONTROL
(IN OPERATION

DISCHARGE ACTIVITY
SINCE 1974)
OPERATION
INFRA RED
CONTROL

RESULTS
ANALYSIS IN
GROUNDING
VIBRATION-

HARMONIC
CURRENT’
ACOUSTIC
SPARKING

CONTROL
ARCING
PD

MOTOR COMPONENTS
Stator winding 10 10 10 10 10 10 10
Current lead 10 10 10
Terminal box Insulation 10 10 10 10
Contacts 10 10
Magnet core 10 10 10 10
0
Rotor 1 10 10
Bearings
Terminator 10 10 10 10
Cable line
Line 10
FINAL CONCLUSION 10
According to discharge activity control results, the technical condition in relation to discharge activity
level is 10 (no risk), vibration and infrared control - 10.
Vibration control results according to capacitive current analysis of this motor are given in Fig. 5, their
distinctive characteristics and analysis are given in descriptions below the figures. Data on vibration
velocity harmonic analysis are not given here as there were no relevant vibration defects.
Below there will be given an analysis of vibration defects for motor No”6-2”:
1) In the 0-170Hz band for harmonics analysis of sub harmonics and harmonics of the reverse
frequency (11, 2 Hz): - “a” curve (capacitors current analysis) gives a presence of sub harmonics ½ fsh
(Defect #1) as well as 3rd fsh for (Defect #3) and 9 fsh (Defect #4); - “d” curve (vibration velocity) is
showing the maximum magnitude for ½, 1, 3, 4, 5, 7, 8 fsh harmonics, measured in point 1.
Conclusion: there are serious shaft misalignments (motor-compressor), bad coaxiality, no parallelism,
fracture, etc, which brings to cutting of harmonics of reverse frequency – the point with the highest
vibration magnitude for defects #1, #2, #3 is situated in the lower bearing.
2) In the 100-500Hz band for harmonics analysis of industrial frequency 50 Hz), as well as for the area
of satellites:
(50 × n) ± (fsh × m){1}
“b” curves (capacitors current analysis) indicate the presence of the following defects in harmonics
spectrum: defect #5 – (200÷280Hz), defect #6 – (400÷450Hz).
“e” curves show the harmonics spectrum for vibro velocities in the point 4 (see Fig. 4), where is the
maximum magnitude fin frequency band or defects #5 and #6.
Conclusion: point No 4 has mechanical friction defects
3) In the 500-5000Hz band for harmonics analysis of defects caused by shock waves (sound). Defect
zones in the frequency band: defect #7 – (2000-2500Hz); defect #8 – (3300-3700Hz); defect #9 – (4500
– 4400Hz).
The f curves for point 4 (see Fig. 4) give multiple spectral lines part of which is connected to the active
part on the motor (bands: 200-2500; 3300-3700;4500-4700Hz) whereas the other part is of external
origin, shock defect from the outside on the motor surface or on the bearing, or connecting sleeve of the
compressor shaft.
Final result of the vibration analysis is illustrated by Fig. 7.

Fig. 6. Location of places with the maximum vibration according to the measurement results of vibro
velocity and harmonics analysis of the capacitive currents towards the ground for motor in order to
detect the quantity of probable defects.

8. Discussion
The ongoing trend in the electricity supply industry is to optimize asset management strategies. One
option is to apply a condition-based approach to replace traditional asset replacement policies. That is
best achieved through the application of advanced condition monitoring technology and prediction
techniques allied with a systematic, phased asset managements approach.
By this systematic approach, the cost-benefit of reliability/risk based utility assessment can be greatly
improved. However, by taking into account failure history, current service history, local knowledge of
the network, replacement planning and risk of failures vs. capital/operational expenditure, asset
managements decisions can be made quicker and more efficiently with the use of dedicated decision
support system.
Fig. 7. Harmonics analysis of two events: capacitance currents to ground (upper row, a; b; c) and vibro
velocity (lower row, d; e; f) on which the speed magnitude maximum constants are given according to
location results in 6 spots.
Table 5
Motors Defect Characteristics, Technical Status, Recommendations

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